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Argo Service Manual Engine System

Ontario Drive & Gear Limited. www.odg.com

PH. (519)- 662-2840 FAX (519)- 662-2421 EN-1

SECTION EN

Engine System

Table of Contents

Briggs V Twin, Kawasaki L/C & Kohler Engine Photographs....... EN-2

General Instructions............................................................................. EN-3

Checking the Engine Oil.......................................................................EN-4

Recommended Engine Oil.................................................................... EN-4

Changing the Engine Oil...................................................................... EN-5

Draining the Engine Oil........................................................................EN-5

Oil Filter Replacement..........................................................................EN-6

Refilling the Engine...............................................................................EN-7Air Filter.................................................................................................EN-7

Spark Plugs............................................................................................EN-7

Removing the Engine(Kawasaki FD620D L/C)..................................EN-8

Assembling the Engine to the Power Pack Frame (Kawasaki).........EN-13

Installing the Engine............................................................................. EN-14

Removing the Engine(Briggs Models).................................................EN-18

Installing the Engine (Briggs Models)................................................. EN-20

Removing the Engine (Kohler Aegis) Supplement Pages................ EN-20A

Installing the Engine (Kohler Aegis) Supplement Pages.................. EN-25A

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Engine System Argo Service Manual

Ontario Drive & Gear Limited www.odg.com

PH. (519)- 662-2840 FAX (519)- 662-2421 EN-2

Briggs& Stratton V Twin OHV 16, 18 & 23 H.P

Kawasaki FD620D Liquid Cooled Kohler Aegis

20 H.P OHV 26H.P Carburated & 31H.P EFI

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-3

General Instructions

Detailed information on standard workshop and safety procedures, and general

servicing operations is not included in this manual, which has been prepared to

assist qualified service personnel. ODG assumes no responsibility or liability for

PERSONAL INJURYor VEHICLE DAMAGEwhich results from any servicing

procedure performed, including those instructions outlined in this manual. Before

performing a servicing operation, an individual must have determined to his/her

satisfaction that personal injury or vehicle damage will not result from the servicing

procedure or tools selected.

All engine service work should be performed by a qualified mechanic. Severe

damage and/or reduced performance can result from an improperly serviced engine.

Basic engine servicing information is provided in this section of the manual. For

more detailed servicing operations please refer to the proper engine service manual

listed in the chart below.

Models Engine Engine Service Manual Part Number

S, SN, BF, F Briggs & Stratton Briggs & Stratton Repair 670-33RB, R, B, N V Twin OHV 16,18 & 23H.P Manual V Twin OHVN 670-40-1

(23H.P)

C, CB, A Kawasaki FD620D Four Stroke Liquid Cooled 99924-2030-03Kawasaki Service Manual

NV, NH Kohler Aegis 26 & 31H.P Kohler Service Manual TP-2527-A

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-4

Recommended Engine Oil

Engine Oil Information

Checking the Engine Oil Level

The BRIGGS & STRATTON VANGUARD (Figure EN-1) and KAWASAKI engines

(Photo EN-2) are equipped with a dipstick and a separate oil filler tube. To check the oil

level, clean the area around the dipstick before removing. Remove the dipstick and wipe

it with a clean cloth. Re-insert the dipstick and push it all the way into the tube. Remove

the dipstick and check the oil level. The oil level should be between the marks. If the

level has dropped, add oil to bring the level up to the FULL mark. DO NOT

OVERFILL.

EN-2

Do not run the engine if the oil level is above the FULL mark or below the ADD

mark. Premature engine damage or total engine failure can occur when the oil level

is not properly maintained.

EN-2a

To check the oil during an operating period, shut the engine off, let it cool down and allow

the oil time to drain into the sump before checking the oil level. Position the vehicle so

the engine is level.

Check the engine oil level each day before operating the engine.

EN-1

Use a high quality detergent oil of API

(American Petroleum Institute) service class

as listed below. Choose the correct viscosity

of oil for seasonal driving conditions. See

chart following page.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-5

Briggs & Stratton API Service Class SE, SF or SG

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-6

IMPORTANT

When draining the oil on the Briggs 18h.p or 16 h.p V Twin engines, it is advisable to

remove it from the drain plug located between the engine and transmission (same

side as the oil filter). To provide a good view of the draining area and avoid any

spills into the lower body, it is best to remove the driven clutch and drive belt as well.

Remove the clamp securing the brake cooling duct to its mounting bracket and tilt itup and out of the line of view of the drain plug area. Position the container beneath

the drain plug and remove the plug. Refer to Removing the Drive Belt and

Removing the Driven Clutch in section CS of this service guide if necessary.

During the initial engine break-in period, change the oil after the first 8 hours of operation

for Briggs & Stratton and 20 hours of operation for the Kawasaki. After the break-in

period, change the engine oil every 50 operating hours, or more frequently if the vehicle is

operated in dusty or dirty conditions.

Changing Engine Oil

Draining the Engine Oil

Each engine is equipped with a drain plug for draining the oil. The drain plug location for

the Kawasaki FD620D and Kohler Aegis engines is beneath the driver clutch.Photo EN-

2a Remove the drive belt for easier access to the drain plug.

1. Start and warm up the engine so the oil will drain easily.

3. Place a suitable container under oil drain of engine and remove drain plug with a

wrench: an 8 point 7/16" square socket for Briggs & Stratton engines or a 21mm

socket for Kawasaki engines.

2. Level the vehicle so the oil will drain completely.

The oil drain plug on the Briggs and Stratton engine is located at both the front and rear of

the engine block. The rear plug on the Briggs & Stratton engine is the recommendedchoice for draining the oil (same side as the oil filter). See IMPORTANT on the following

page.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-7

There is limited space between the engine and power pack frame. Cut down an empty

plastic container to the correct height so it will fit under the engine oil drain. Make sure

the container will hold the amount of oil in the engine.

A ziploc plastic bag makes a convenient oil container. It conforms to the space available

and can be closed securely when the oil is drained, then lifted neatly out of the engine

compartment.

4. When all the oil has been drained from the engine, clean and replace the drain plug.

MAKE SURE it is properly tightened before refilling the engine.

5. See Oil Filter Replacement Below.

PLEASE DISPOSE OF WASTE OIL PROPERLY TO CONSERVE OUR ENVI-

RONMENT.

Oil Filter Replacement

During the initial engine break-in period, change the oil filter (Part No. 126-95 for Briggs

& Stratton engines and Part No. 127-68 for Kawasaki engines) when the oil is changed.

After that, change the oil filter every 50 hours.

Before installing the new filter, lubricate the rubber filter gasket with fresh engine oil.

Screw the filter on by hand until the gasket contacts the filter adapter. Tighten 1/2 to 3/4

turn more. Add the specified oil. See previous page for oil capacities based on the engine

powering your vehicle. Start and run engine to check for oil leaks. Stop engine and re-

check oil level. Add oil if required.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-8

Refill the engine through the oil fill port with the correct amount of oil (Photo EN-1 & 2

on pageEN-4). Make sure the appropriate grade of oil is used (page EN-5). As you add

oil, frequently check the level with the dipstick. Do not overfill. Start engine. Check for

leaks. Stop the engine. Check the oil level. Add oil only to the Full or H mark onthe dipstick.

Refilling the Engine

Air Filter

Spark Plugs

When replacing spark plugs on the Kawasaki FD620D Liquid Cooled OHV Engine,

it is extremely important to pay strict attention to the specification number of the

engine being serviced. All Conquest vehicles manufactured prior to vehicle serial

number CB17857 require spark plug part number 92070-2072. Vehicles produced

from CB17857 with a specification number of HS12 or later require spark plug

number 92070-2112.

Kawasaki has made changes to the Cylinder Heads, Head composition, & spark plugs

of the FD620D. The newer spark plugs are longer and will cause damage if used in

an older spec. engine.

All ARGO engines are equipped with a foam precleaner and dry paper air filter element

housed in an air cleaner assembly attached to the carburetor.

Wash and oil the precleaner after every 25 hours of operation or more often under

extremely dusty or dirty conditions.

Check the paper air filter element every 100 hours of operation or more often underextremely dusty or dirty conditions.

For instructions to remove, clean and replace the air filter components, refer to the air

cleaner section of the engine owners manual.

Remove and inspect the spark plugs after every 100 hours of operation. Clean the plugs

and reset the gap as detailed in the engine owners manual.

Replace the spark plugs if the electrodes are corroded or damaged or if the insulator is

cracked. Use the correct plug for the engine as detailed in the engine owners manual.

Re-install the spark plugs carefully, taking care to start the threads properly. Torque the

plugs to 10 - 15 ft. lbs (14 to 20 Nm). Do not over tighten.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-9

Removing the Engine (FD620D Kawasaki Liquid Cooled OHV)

Accessing the 4 mounting bolts that secure the engine to the power pack frame requires

the power pack frame to be removed from the vehicle. Both engine and transmission canbe removed through the engine access opening using an overhead hoist. You may prefer

to remove the transmission first before lifting engine and frame through the hood area..

2. Locate and remove the engine access cover. Photo EN-3

3. Separate the main wire harness from the nylon clips securing it at the back of the

engine. Photo EN-4

EN-3 EN-4

4. Disconnect the main engine wire harness plug located between engine and transmis-

sion. Photo EN-5

5. Remove the starter cable at the electric starter. Photo EN-6

EN-5 EN-6

1. Perform the servicing procedure, Removing the Battery in section ES of this serv-

ice guide.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-10

6. Disconnect the ground wire (leading from the battery ground terminal post), at the

engine.

7. Remove the radiator overflow bottle at the front of the engine.

Conquests manufactured prior to CB14963 have an O.D.G overflow bottle and holder to

remove. Conquests manufactured from CB14963 utilize a Kawasaki bottle secured

directly to the upper radiator bracket.

8. Unclip the fuel line from the nylon clips at the front of the engine.

9. Remove the engine air filter cover and air element. Photo EN-7

10. Remove the 7 fasteners securing the plastic base of the air filter housing.Photo EN-8

EN-7 EN-8

When removing the 3 fasteners securing the base closest to the mouth of the

carburetor, be aware of the 3 metal inserts in each mounting hole. These may pull

out when removing the fastener. Caution is advised to ensure that they do not fall

into the throat of the carburetor undetected. Severe engine damage will occur if this

has not been observed.

11. Remove the 2 nuts securing the lower metal base of the air filter system to the

carburetor, and remove.

Once the metal base has been removed, temporarily reinstall the 2 nuts to secure the

carburetor lid.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-11

12. Disconnect the fuel line at the carburetor. Photo EN-9

13. Disconnect the choke at the dash.

EN-9 EN-10

On Conquests manufactured prior to CB14606, remove the molded panel nut at the dash

and slip the assembly back through the body into the engine compartment.

14. Perform the servicing procedure, Removing the Muffler and Shroud (Conquest),

steps 1-6 on page DE-3 (models prior to C19672) or steps 1-2 on page DE-7 (mod-

els from C19672).

15. Disconnect the intake hose at the brake cooling duct. Photo EN-11

16. Remove the front pivot mounting bolt securing the power pack frame to the lower

main frame. Photo EN-12

Conquests manufactured from CB14606, require that the choke be disconnected at the

throttle/choke control panel.Photo EN-10 The choke knob is molded to the end of the

cable and does not thread off.

IMPORTANT

Before proceeding any further, be sure to cover the mouth of the carburetor with arag, or other option. This will prevent anything from entering the carburetor

unintentionally.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-12

EN-12

EN-11

17. Perform the servicing procedure, Removing the Drive Belt in section CS of this

service guide.

18. Perform the servicing procedure, Removing the Driven Clutch, in section CS of

this service guide.

20. Locate the (3) mounting bolts that secure the steering and master cylinder assembly

to the transmission and remove them. Photo EN-13

21. Disconnect the wiring at the igniter box which is mounted to the steering assembly.

Photo EN-14

EN-13EN-14

22. Unfasten the twist grip assembly from the steering handle and remove it.

Photo EN-15

19. Perform the servicing procedure, Removing the Brake Pads ( Hydraulic ) steps 1-

4, in section BR of this service guide.

23. Remove the entire hydraulic brake system from the vehicle. The calipers, master

cylinders and brake lines can all remain attached without the loss of any brake fluid.

Photo EN-16

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-13

25. Loosen off the 2 power pack mounting bolts that run through the power pack frame

and connect it with the lower main frame. One is located in front of the idler shaft,

the other behind. Photo EN-17

26. Loosen off the dash support and turn it 90 degrees. Photo EN-18

28. Attach an overhead hoist to the front

engine hook only. This hook is located

on the exhaust manifold. Photo EN-20

24. Perform the servicing procedure, Idler Chain Removal, in section WA of this serv-

ice guide.

EN-15 EN-16

EN-18EN-17

27. Remove the driven clutch guard from

the transmission. It is secured with (2)

bolts and (2) flatwashers.

Photo EN-19

EN-19

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-14

29. Gradually and gently begin to raise the power pack assembly out of the engine ac-

cess opening. Photo EN-21 You may have to pry the transmission from the drivers

compartment to free it from the lower main frame.

EN-20 EN-21

30. Set the power pack on a clean work bench and remove the 4 bolts that secure theengine to the frame. These bolts are threaded into the engine block from below.

Photo EN-22

31. Using the overhead hoist, remove the engine from the power pack frame.

Photo EN-23

EN-22 EN-23

If the engine is being replaced, you will need to remove all Argo components that are notavailable with the new engine. These will need to be reassembled to the new engine.

Components include, throttle cable, choke cable, exhaust manifold, driver clutch, etc.

Assembling the Engine to the Power Pack Frame (Kawasaki)

1. Position the engine on to the power pack frame and align the holes in the block with

the holes of the frame. Photo EN-24

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-15

2. Apply blue 242 LOCTITE to the threads of each mounting bolt and install. Torque

to specifications.

3. Attach the overhead hoist to the front engine hook and lower the power pack into the

vehicle through the engine access opening. The power pack assembly will go invertically with the transmission entering the vehicle first. Photo EN-25

EN-24

IMPORTANT

As the power pack is lowered into the vehicle, position yourself inside the drivers

compartment. Lift up on the transmission and align the power pack frame with the

vehicle main frame.

4. Position the power pack frame on to the lower main frame and install the front

mounting pivot bolt. Be sure to install the square lockwasher to the mountng bolt

head.Photo EN-26. The bolt is installed from left to right when standing at the

front of the vehicle.

5. Assemble the rear power pack mounting bolt, complete with spacers and

square washers, through the power pack frame. Photo EN-27

EN-26 EN-27

Installing the Engine (Kawasaki FD620D L/C)

EN-25

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-16

6. Lower the rear of the power pack frame aligning the mounting bolt with the main

frame. Photo EN-28

7. Install the 3rd mid mounting bolt paying close attention to the hardware that is re-

quired along with it. See your illustrated parts manual. Photo EN-29

EN-28 EN-29

On vehicles manufactured prior to serial

number CB17117, ensure that the air intake

duct seal at the radiator, is properly seated

back up against the face of the radiator

assembly. Photo EN-30.

EN-308. Reconnect the hose at the brake cool-ing duct.

9. Perform the servicing procedure, Installing the Muffler and Shroud (Conquest

Models), in section DE of this service guide.

ii. Slip the over flow bottle back into the holder and connect the hose.

On Conquests manufactured prior to CB14963:

i. Reattach the radiator overflow bottle holder at the front of the engine.

On Conquests manufactured from CB14963:

i. Attach the radiator over flow bottle directly to the upper rad bracket installing the 2

required spacers at each mounting bolt. re-insert the overflow hose.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-17

10. Reconnect the fuel line at the carburetor and secure with the hose clamp.

11. Secure the fuel line to the nylon clips at the front of the vehicle.

12. Assemble the lower metal air filter plate to the top of the carburetor. Photo EN-31

13. Assemble the plastic air filter base to the top of the previously installed metal back-ing plate, Photo EN-32, being sure to reconnect the tube from the base to the air

breather assembly on top of the engine.

EN-31 EN-32

14. Reinstall the air filter element with foam precleaner, and assemble the cover to the

top of the engine.

15. Reconnect the main engine wire harness located between the engine and transmis-

sion.

16. Reconnect the starter cable at the electric starter and cover with the rubber boot.

17. Secure the main engine harness to the nylon clips between the engine and transmis-

sion.

18. Reconnect the ground wire from the negative battery post terminal to the engine.

19. Reconnect the choke cable assembly.

On Conquests manufactured prior to CB14606, slip the assembly back through the body

at the dash and secure with the molded panel nut. It was not required that the choke was

disconnected at the throttle/choke control panel for engine removal, but if it was, you will

need to reattach it at the linkage as well.

On Conquests manufactured from CB14606, reconnect the cable to the throttle/choke

control panel. It was not required that the choke knob was removed at the dash when the

engine was prepared for removal..

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-18

20. Reposition the adjustable dash support

back down to the top of the transmis-

sion and secure the carriage bolt. Photo

EN-33

21. Perform the servicing procedure, IdlerChain Installation and Idler Chain

Adjustment in section WA of this serv-

ice guide.

22. Reinstall the steering assembly to the transmission securing it with 3 bolts and

lockwashers. Photo EN-34

23. Reattach the hydraulic brake calipers. Apply blue 242 Loctite to the threads of the

mounting bolts and torque to specifications. See step 2 ofInstalling the Brake

Pads (Hydraulic), if necessary.

EN-33

EN-34

24. Reconnect the ignition system at the ig-

niter box.

25. Reinstall the clutch guard. Apply blue

242 LOCTITE to the threads of the 2

bolts that secure it to the transmission.

Install each bolt with 2 flat washers

Torque to specifications.

26. Perform the servicing procedure, In-

stalling the Driven Clutch, In section

CS of this service guide.

27. Perform the servicing procedure, Installing the Drive Belt, In section CS of this

service guide.

28 Perform the servicing procedure, Hydraulic Brake Plunger Adjustment, in section

BR of this service guide.

30. Perform the servicing procedure, Installing the Firewall, in section VB of this

service guide. See IMPORTANT on following page.

29. Perform the servicing procedure, Installing the Battery, in section ES of this serv-

ice guide and reconnect the wiring.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-19

IMPORTANT

Ensure that all levels of fluid (oil and antifreeze), in engine are correct before

starting the vehicle. Run the engine for 5 minutes and recheck all levels. Add or

remove as necessary.

Removing the Engine (Briggs & Stratton 16 h.p & 18h.p)

Unlike the Kawasaki FD620D L/C OHV engine, the Briggs & Stratton 16h.p and 18h.p

engines may be detached from the power pack frame without having to remove the frame

from the vehicle to access the mounting bolts. The engine may then be lifted

independently through the engine access opening using an overhead hoist. However,

initial preparations and disassemblies must be followed first.

1. Perform the servicing procedure, Removing the Firewall, in section CS of this

service guide.

2. Remove the hood.

3. Disconnect and remove the battery.

4. Perform the servicing procedure, Re-

moving the Air Intake Shroud

(Briggs Models), in section DE of this

service guide.

6. Perform the servicing procedure,

Driven Clutch Removal, in section CS

of this service guide.

7. Remove the driven clutch guard.

8. Disconnect the hose at the brake cool-

ing duct.

9. Remove the gear clamp that secures the

brake cooling duct to its mountingbracket, located between engine and

transmission. Remove the duct.

10. Perform the servicing procedure, Removing the Muffler(Briggs models) on page

DE-11 (Bigfoot models) or DE-8 all other Briggs models.

11. Unplug the charging wire at the front of the vehicle. Photo EN-35

EN-35

12. Disconnect the isolated ground wire at the front of the engine. Photo EN-36

5. Perform the servicing procedure,

Removing the Drive Belt, in section

CS.

EN-36

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-20

15. Locate the fuel filter at the front of the vehicle and disconnect the fuel line. Be sure

to clamp the fuel line with fuel line crimpers to prevent any fuel from leaking from

the tank into the lower body.IMPORTANT

Never stick anything into the fuel line to plug it. This could damage the fuel line

leading to stray pieces of fuel line rubber being introduced into the fuel system when

the fuel line is reconnected.

16. Disconnect the ground cable at the engine. Photo EN-37

18. Remove all 4 mounting bolts at the lower frame. The engine is secured with 4 ny-

lon locknuts.

19. Lift the engine out of the vehicle using an overhead hoist. Photo EN-38

EN-37 EN-38

On vehicles manufactured prior to BF12097, RB17665, S12222 & SN12227:

i. Disconnect the starter cable at the starter motor.

On vehicles manufactured from BF12097, RB17665, S12222 & SN12227:

i. Disconnect the power cable at the starter relay. The starter relay is attached to the

front of the engine close to the regulator.

17. Disconnect the power cable for the electric start.

If the engine is being replaced, all Argo components must be removed first and reinstalled

on the new engine. These include driver clutch, muffler, exhaust manifold and any return

springs.

13. Disconnect the throttle cable at the engine.

14. Disconnect the choke at the engine.

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-21

2. Secure the engine to the power pack

frame with 4 bolts, 8 flat washers and 4

nylon locknuts. Refer to the illustrated

parts manual for correct hardware ori-

entation. Torque to specifications.

IMPORTANT

You will notice 8 mounting holes in the block of the engine. It is important that the

correct set of holes is used for clutch offset and belt alignment. Use the holes asillustrated inPhoto EN-40 & 41 below.

3. Reconnect the power to the electric starter.

Installing the Engine (Briggs Models)

1. Attach the overhead hoist to both en-

gine hooks and lower the engine into

the vehicle. Photo EN-39

On vehicles manufactured prior to BF12097, RB17665, S12222 & SN12227:

i. Connect the starter cable at the starter motor.

On vehicles manufactured from BF12097, RB17665, S12222 & SN12227:

i. Connect the power cable at the starter relay.

Reattach the clip that secures the starter cable at the front of the engine.

EN-39

EN-41EN-40

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PH. (519)- 662-2840 FAX (519)- 662-2421 EN-22

4. Reattach the ground wire to the isolated ground at the front of the engine, and plug

the charging wire from the main wire harness back into the engine wire harness.

5. Reconnect the fuel line at the fuel filter.

6. Place the brake cooling duct to the top of the mounting bracket and secure with the

gear clamp.

7. Reattach the brake cooling hose to the brake cooling duct and secure with another

gear clamp.

8. Assemble the choke cable to the carburetor linkage. Photo EN-42

9. Assemble the throttle cable to the carburetor linkage. Photo EN-43

EN-42 EN-43

10. Reattach the ground wire running fromthe battery terminal, back to the engine.

Photo EN-44

11. Perform the servicing procedure, Install-

ing the Muffler (BriggsModels),on

page DE-11 (Bigfoot)or DE-10 (others).

EN-44

12. Mount the driven clutch guard at the

transmission. Apply blue 242 LOCTITE

to the threads of both mounting bolts andinstall with 2 flat washers. Torque to

specifications.

13. Perform the servicing procedure, Installing the Driven Clutch in section CS of this

service guide.

14. Perform the servicing procedure, Installing the Drive Belt, in section CS of this

service guide.

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15. Perform the servicing procedure, Installing the Intake Duct (Briggs Models), in

section DE of this service guide.

16. Install the battery and reconnect battery terminals.

17. Perform the servicing procedure, Installing the Firewall, in section VB of this

service guide.

IMPORTANT

Before starting the engine check the engine oil level and re-check all electrical

connections.

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Ontario Drive & Gear ltd. www.odg.com/centaur

(519) 662-2840 FAX (519) 662-2421

SECTION EN

Supplement Pages

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Ontario Drive & Gear ltd. www.odg.com/centaur

(519) 662-2840 FAX (519) 662-2421

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1. Locate the tailpipe assembly and detach the connecting springs between the tailpipe

assembly and muffler. Photo 1 & 2 Pull the assembly out through the hood area.

1 2

2. Remove the heat deflector shield covering the muffler. Photo 3

Disconnect All Wiring

3. Disconnect the fuel line from the fuel filter at the carburetor. Photo 4

3 4

4. Disconnect the ground cable at the engine. Photo 5 & 6

Removing the Engine (Kohler Aegis N.A)

5 6

EN-20A

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5. Disconnect the ground wire attached at the front of the engine to the valve cover

fastener.Photo 7

6. Locate the main wire harness plug-ins at the front of the engine compartment and

disconnect all wires. Photo 8

7 8

7. Locate the starter at the front of the engine compartment and disconnect both red

and black power wires from the starter solenoid. Photo 9 These wires are enclosed

within a red rubber boot.

9 10

8. Remove the drive belt between engine and transmission. Photo 10

9. Remove the driven clutch from the transmission input shaft.Photo 11 & 12

12

11

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10. Disconnect the brake cooling hose at the brake duct. Photo 13

16

Removing The (4) Engine MountFasteners

17

12. To effectively and efficiently remove

the nylon locknuts that are securing the

engine to the power pack frame studs, a

flat ratcheting style wrench is the rec-

ommended tool of choice. Photo 16

This type of wrench is preferred for removing 3 of the 4 nylon locknut fasteners. The

exception is the fastener located at the rear left corner of the engine block (as viewed by

the operator in the drivers seat). This fastener requires the use of a regular opened end

style wrench.

13. Remove each nylon locking nut and flat washer. Photo 17

11 Disconnect the choke & throttle cables from the control panel on the Kohler engine.

Photo 14 & 15 Make note of which hole the throttle cable is inserted.

13 14

15

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Lifting the Engine From the Vehicle

This procedure requires the use of an overhead hoist. Do NOT attempt to lift out by

hand. Ensure all components attached to the engine have been detached. Lift out

slowly and carefully. If you wish to remove the muffler from the engine beforeraising it out, you may do so as an optional procedure. You may find it easier to

maneuver the engine up and out with the muffler removed, but it is not necessary.

Ensure all hoist chains or belts are secure, and hooks are locked into place. Keep all

fingers and hands clear of the area from which the engine is being lifted.

14. Attach the overhead hoist to the engine. There is a hook provided on the engine

Photo 18, (located near the yellow oil fill plug on earlier spec. engines and beside

the rear cylinder head cover on later spec. engines),for connecting one side of the

hoist chain. Connect the other side to the rad bracket.Photo 19

18 19

15. Slowly and gently raise the engine through the hood area. Some manuevering is

required as the engine does not necessarily come straight up and out. Avoid damage

to any other components as well as the upper body. Photo 20 & 21

20 21

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PH. (519)- 662-2840 FAX (519)- 662-2421

16. Remove the engine to a clean workbench for further disassembly.

17. Remove the muffler if it was not previously removed. (EFI models will have an O2

sensor threaded into the muffler that will need to be removed as well. Photo 22

18. Remove the hex head fastener securing the driver clutch to the PTO and slide the

clutch from the shaft. The PTO is a keyed shaft. Photo 23 & 24

19. Remove the (5) shims that are installed to the PTO. Photo 25

IMPORTANT

These shims MUST be reinstalled before the driver clutch.

22 23

24 25

20. Remove all fluids.

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Installing The Engine (Kohler Avenger Model)

1. Install the (5) shims to the PTO of the engine. Photo 1

2. Apply anti-seize compound to the PTO. Photo 2

3. Install the key to the keyway of the PTO. Photo 3

4. Slide the driver clutch on and up to the shoulder of the PTO. Photo 4

1 2

3 4

5. Secure the driver with the hex head fastener. Apply blue LOCTITE and Torque to

specifications. Photo 5

For part number and descriptions of all components and hardware, always refer toyour illustrated Argo parts manual.

IMPORTANT

6. Install the muffler assembly to the engine manifold. Photo 6

IMPORTANT

Always use new manifold gaskets

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5 6

IMPORTANT

If you have removed the Kohler Aegis radiator assembly from the engine for any

reason (repair, replacement etc.), ensure, when reinstalling it, that you tie-wrap the

bottom of it securely to the lower bracket as in photo 7 & 8. This will prevent thelower radiator locating pins from dislodging from the rubber gromments under

heavy vehicle application. Damage can occur to both fan and shroud if this is not

done. Please note that later spec. engines have retaining clips installed to the

locating pins and do not require the tie-wraps to secure the rad in place.

7 8

7. Attach the hoist hooks to the engine lo-

cation as described in 14 ofRemov-

ing The Engine.

8. Swing the engine assembly over the

open hood area of the Avenger vehi-

cle. Locate the (4) mounting studs on

the power pack frame. Photo 99

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9. Slowly and gently lower the engine through the hood area. Some manuevering is

required as the engine does not necessarily drop in straight on. Avoid damage to any

vehicle components as well as the upper body. Photo 10 & 11

1110

IMPORTANT

Align the mounting holes of the engine block with the powerpack frame studs. Once

aligned properly, the engine should just drop into place. Do not force or hammer in

any way. Damage may occur to the threads of the mounting studs.

IMPORTANT

Once the engine is seated into place, ensure that the rubber rad seal is properlysealing at the face of the radiator. Photo 12

12

10. Locate the flat washer and nylon locknut used to secure the engine to the power

pack frame studs.Photo 13 Refer to your illustrated parts manual. Install all

four fasteners and Torque to specifications. Refer to step 12 of Removing The

Engine, for preferred wrenches used to retighten the nylon locknuts.

13

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11. Reconnect the brake cooling hose at the brake duct. Photo 14

12 Reconnect the choke & throttle cables to the control panel on the Kohler engine.

Photo 15 Insert the throttle cable into the correct hole.Photo 16

14 15

16

14. Install the driven clutch. Apply blue

LOCTITE to the threads of the fastener

and Torque to specifications. Photo

18

17

13. Assemble the key to the keyway of the

transmission input shaft. Apply anti-

seize compound to the length of the

shaft.Photo 17

1815. Reinstall the drive belt between engine

and transmission.

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16. Locate the starter at the front of the engine compartment and reconnect both red and

black power wires to the starter solenoid. Photo 19 These wires are enclosed

within a red rubber boot.

17. Reconnect the ground wire attached at the front of the engine to the valve cover

fastener.Photo 20

18. Locate the main wire harness plug-ins

at the front of the engine compartment

and reconnect the main black plug. Re-

connect both blue and orange wires

(oil pressure and coolant temperature

sensors). Photo 21

19 20

21

19. Reconnect the ground cable at the

engine. Photo 22 & 23

2322

20. Reconnect the fuel line to the carburator. Photo 24

21. Reinstall the heat deflector shield over the muffler. Photo 25

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24 25

22. Locate and install the tailpipe assembly. Attach the connecting springs between

tailpipe assembly and muffler. Photo26 & 27 Feed the tailpipe assembly in

through the hood area.

26 27

23. Replenish all fluid levels.

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